WO2013095984A1

WO2013095984A1 - Improved method of producing two or more thn-film-based interconnected photovoltaic cells

Info

Publication number: WO2013095984A1
Application number: PCT/US2012/068864
Authority: WO
Inventors: Rebekah Kristine-Ligman Feist; Michael E. Mills
Original assignee: Dow Global Technologies LLC
Current assignee: Dow Global Technologies LLC
Priority date: 2011-12-21
Filing date: 2012-12-11
Publication date: 2013-06-27
Anticipated expiration: 2014-06-21
Also published as: JP2015503844A; WO2013095984A8; CN104011877A; IN2014CN04529A; BR112014015069A8; EP2795676A1; KR20140105019A; MX336866B; US20140345669A1; MX2014007656A; BR112014015069A2

Abstract

The present invention is directed to a method of producing two or more ihin- fi] m- feased interconnected photovoltaic cells (100) comprising the steps of: a) providing a photovoltaic article comprising: a flexible conductive substrate, at least one photoelectrically active layer, and a top transparent conducting layer; b) forming one or more first channels (140) through the flexible conductive substrate to expose a portion of the photoelectrical] ? - active layer; e) applying an insulating segment to the conductive substrate and spanning the one or more first- channel; d) forming one or more second channels off set from the one or more first channels- 'through -the photoelectrically active layer to expose a conductive surface of the flexible conductive substrate; I) forming one or more third channels (170) off set from both the first channels and the second channels, through the top transparent conducting layer and to the photoelectrically active layer: and g) applying an electrically conductive material (180) above the top transparent conducting layer and in the second channels, thus producing two or more Interconnected photovoltaic eelis..

Description

IMPROVED METHOD OF PRODUCING TWO OR MOm THI &U*-BA$gD

I TERCONNECTED PHOTOVOLTAIC CELLS

FIELD OF THE INVE TtON

[001] The present invention relates to an improved: method of producing: two or more thih-fiim-based. interconnected photovoltaic cells, mora particularly to an Improved method of producing two or more thin -film-based interconnected photovoltaic ceils from a photovoltaic article that includes a flexible conductive substrate, at least one photoeleetrically active layer, and a top transparent conducting layer,

BACKGROUND

|O02] Efforts to improve the manufacture of photovoltaic devices, particularly tbin-fiim- based Interconnected photovoltaic ceils have been the subject of much research and development of the recent past. Of particular interest is the ability to manufacture thin- film-based interconnected photovoltaic cells In a variety of shapes and sizes, white maintaining efficient production and a relatively low capital investment, thus making the finished product more affordable. It has been a. goal of the industry to develop these process and techniques that can help make the finished product more affordable, -while still producing duality product.

O03J In one application, these Ihin-film-based interconnected photovoltaic cells are used as the electricity generating component of larger photovoltaic devices. The available shapes and si2es of relatively low cost thin-film-based interconnected photovoltaic cells may limit the design of the larger photovoltaic devices and systems of devices, and thus the possible market for them. To make this full package desirable to the consumer, and to gain wide acceptance i the marketplace, the system should be inexpensive to build and install. The present invention ultimatel may help facilitate lower generated cost of energy, making PV technology more competitive relative to other means of generating electricity,

[004! If is believed that the existing art for the manufactur of thin-film-based interconnected photovoltaic cells have relied upon methods and techniques that utilize interconnect steps prior to the completing of the- photovoltaic article, for example wherein at least one scribe or cut is made during the article fabrication process,

[O05J Among the literature that can pertain to this technology include the following literature and U,S, patent documents; F. Kessler et a!, "Flexible and moholiihlcaJf integrated CIGS-moduies", MRS 866: H3.&1-H3.6.6 (2001 ); 4,754,544; 4,897,041 ; 5,131 ,954; 5,639,314; 6,372,538; 7,122,398; and 201 G/1236490, ail incorporated herein by reference for all purposes.

SUM ARY OF THE INVENTION

[006] The present invention is directed to a PV device that addresses at least one or more of the issues described in the above paragraphs,

[007] Accordingly, pursuant: to one aspect of the present invention_s there is contemplated a method of producing two or more thin-film-based Interconnected photovoltaic cells comprising the steps of; jprovidlng a photovoltaic article comprising: a flexible conductive substrate:,, at least one photoelectnealiy active layer, and a top transparent conducting layer; b) forming one o more first channels through the flexible conductive substrate to expose a portion of t e photoelectricity active Iayer; c) applying an insulating segment to the conductive substrate lower layer and spanning the one or more first channel; d) forming one or more second channels off set from the one or more first channels through the photoeloetrseaiiy active layer (and preferably also through the transparent conducting layer) to expose a conductive surface of the flexible conductive substrate; f) forming one or more third channels off set from both the first channels and the second channels, through the top transparent conducting layer and to the photoeleetricaiiy active layer; and g) applying a electrically conductive material above the top transparent conducting layer and in the second channels, thus producing two or more interconnected photovoltaic cells,,

[008] The invention may be further characterized by one or any combination of fhe features described herein, such as the ste of at least partially filling the at least one third off-set channels with an electrically insulating material; the electrically insulating material comprises silicon oxide, silicon nitride, titanium oxide, aluminum oxide, non- conductive epoxy, silicone, polyester, olyfluprene, polyoiefir?, polyimide, polyamide, polyethylene or combinations of the like: the insulating segment comprises polyester, polyoiefin, polyimide, polyamide, polyethylene; forming step is carried out by scribing, cutting, ablating, or combinations of the like; the photovoltaic article cell is in roii form; the .electrically insulating material functions as bottom carrier illrm the third off-se channels of the forming step (f) go at least partially through the photoelectrical^ active layer; and the width of the channels of the forming: step are between 10 -^» 500 microns,

[00 | it should be appreciated that the abov referenced aspects and examples are ndfi'limittng, as others exist within the present invention, as shown and described herein.

DESGRIPTiOM OF THE mAWlHQS 010] Figure 1 A shows the layers of a photovoltaic article,

[01 Figure I B shows the layers of photovoltaic article with a first channel.

[012| Figure iC shows the laye of a photovoltaic article with a first channel and an insulating layer.

[0133^" Figure I D shows the layers of a photovoltaic article with a first channel, a second channel, a third channel and an insulating layer.

[0143 Figure IE shows the layers of a photovoltaic article with a first channel, a second channel having electrically conductive material therein, a third channel and an insulating: layer,

[015] Figure 2 shows an alternative embodiment of the layers of a photovoltaic article.

DETAILED DESCRIPTION OF THE PBE SRflED EMBODIMENT

[916] The present invention relates to an improved method of producing two or more irihvfilm-based interconnected photovoltaic cells from a photovoltaic article that includes a flexible conductive substrate, at least one photoeiectrica!ly active layer, and a top transparent conducting layer, i is contemplated thai the present inventio provides a unique manufacturing solutio that allows for the creation and interconnection of photovoltaic cells (e.g. two or more} from a photovoltaic article that is essentially already fabricated. The present inventio may allow for thin-fiim-based interconnected photovoltaic : cells with unique shapes and sizes to be manufactured with relatively low capital investment and without dedicated equipment or processes withi the photovoltaic article manufacturing lines. Taught within this disclosure is the inventive method, as well as an explanation of the structure some of the typical photovoltaic articles that may foe used as the inputs to the inventive process. The disclosed photovoltaic article discussed herein -should not be considered limiting on the inventive method and other possible base photovoltaic articles are contemplated.

[017] It is- contemplated that: the inventive method functions to take a base photovoltaic article 10 and transform ¾ into interconnected photovoltaic cells 10Q, independent of the manufacturing of the_: base article. Fig, A Is a representative example of the article 10 and method of this invention. The inventive method includes at least the steps of; a) providing a photovoltaic article CS comprising a flexible conductive substrate 110, at least one photoeleGfricaily active layer 1 0 , and a top transparent conducting layer 130; b forming one or more first channels 140 through the flexible conductive substrate 10 to expose a portion of the phoioeioctricaliy active layer 120; p) applying an insulating segment 50 to the conductive substrate 110 and spanning the one or more first channel 140; d) forming one or more second channels 180 off set from the one or more first channels 1 0 through the photoelectricaUy active layer to expose a conductive surface of the flexible conductive substrate 110; f) forming one o more third channels 170 off set from both the first channels 140 and the second channels ISO., through the fop transparent conducting layer 130 and to the photoelectrical active layer 120; and g) applying an electrically conductive materia! 180 above the top transparent conducting layer and in the second channels, thus producing two or more interconnected photovoltaic cells. Optional steps may include one or more of the following: at least partially filling the at least one third off-set channels with an electrically insulating material; providing a carrier film top layer; removing the carrier film top layer, thus exposing the top contact layer; packaging with protective layers; forming interconnects to external electric devices; packaging in module format fe,g, shingle); or using as part of a photovoltaic cell as described i US Publication 2011/0100436,.

E¾gllggt ^e Artfcle to

[018] It is contemplated that a photovoltaic article 10 is provided in the beginnin of the inventive method process. The article 10 is the basis for the creation of multiple Interconnected photovoltaic ceils 100 through this inventive: method/process. The article should be comprised of at least three layers (list from bottom to top of the article): a flexible conductive substrate 1 10, at least one phoioeiectricaliy active layer 120, and a top transparent conducting layer 139, It is contemplated that the substrate or layers disclosed within this application may comprise a single layer, but any of these independently can be formed from multiple sublayers as desired. Additional layers conventionally used in photovoltaic articles as presently, known or hereafter developed may also toe provided. It is contemplated that presently known photovoltaic articles for us in the present Invention may Include: group IB-liiS ohaicogenide type cells (e,g, copper indium gallium seienides, copper indium seienides, copper Indium gallium sulfides, copper indium sulfides, copper indium gallium seienides sulfides, etc), amorphous silicon, ili-V (i.e, C3aAs), li-tV (i.e. CdTe), copper zinc tin sulfide, organic photovoltaics, nanoparticle photovoltaics, dye sensitized solar cells, and combination of the like.

f¾1 @j Additional optional layers (not shown) may be used on the article 10 in accordanc with conventional practices now known or hereafter developed to hel enhance adhesion between the various layers. Additionally, one or mora barrier layers (not shown) also may be provided over the backside of flexible conductive substrate 110 to help isolate device 0 from the environment and/or to electrically isolate device 10. |020] In one preferred embodiment, t e photovoltaic article 10 provided as the base ^•used in the inventive method process is what is a group lEHHB c aScogenide device. RG. 2 shows one embodiment of a photovoltaic article 10 that may foe used in the processes of the present invention. In the layers describe below, it is contemplated that layers 22 and 24 together comprise the flexible conductive substrate, layer 20 is part of the least one photoeiectrlcaiiy active layer, and layer 30 is part of the top transparent conductive layer. This article 10 comprises a substrate incorporating a support 22, a backside electrical contact 24, and a ohaicogenide absorber 20. The article 10 further includes an buffer region 28 comprising an n-type ohaicogenide composition such as a cadmium sulfide based material The buffer region preferably ha a thickness of 15 to 200 nm. The article may also include an optional front side electrical contact window region 28. This window region protects the buffer during subsequent formation of the transparent conducting region 30. The window preferabl is formed from transparent oxide of zinc, indium, cadmium, or tin and is typically considered -at least somewhat resistive. The Thickness of this layer is preferably 10 to 200 nm. The article further comprises a transparent conductive region 30_:, Each of these components is shown in Fig. 2 a including a single layer, but any of these Independently can be formed from multiple sublayers as desired. Additional layers (not shown) conventionally used i photovoltaic ceils as presently known or hereafter developed may also be provided. As used occasionally herein, the top 12 of the cell Is deemed to be that side which receives the incident light 16, Th method of forming the cadmium sulfide based layer on the absorber can also be used in tandem cell structures where two cells are built en top of each other, each with an absorber that absorbs radiation at different wavelengths.

[021] It Is contemplated that the photovoltaic article 0 has at least a flexible conductive substrate 1 10 that the article is built upon. It functions- to provide a base upon which the other layers of the article are disposed upon. It also functions to provide electrical contact, St Is contemplated that the substrate may be a single layer (e.g. stainless steel) or may foe a multilayer composite of many materials, both electrically conductive and non-conducive layers, ^'Examples -of conductive materials include metals (e.g. Cu, Mo, Ag, Au Al, Or, M , Ti, Ta, Nb, and W), conductive polymers, combinations of these, and the like. In one preferred embodiment, the substrate is comprised of stainless steel that has a thickness that is between about 10 μ?η and 200 urn. St is also preferred that the substrate is flexible., with "flexible" being defined as the "flexible" item, element, or layer (in a usable thickness pursuant to the present invention) that can bend about a 1 meter diameter cylinder without, a decrease in performance or critical damage, 22¾ in the device shown in Fig 2, the flexible conductive substrate comprises layers 22 and 24. The support 22 may be a flexible substrate. Support 22 may be formed from wide range of materials. These include metals, metal alloys, intermetallic compositions, plastics, paper, woven or non-woven fabrics,, combinations of these, and the like. Stainless steel is preferred. Flexibl substrates are preferred to enable maximum utilization of the flexibility of the thin film absorber and other layers.

| 23] The backside electrical contact 24 provides a convenient way to electrically couple article 10 to external circuitry. Contact 24 may be formed f om a wide range of electrically conductive materials, including one or more of Cu, Mo, Ag, Ai, Cr, Hi, Ti, Ta, Nb,_. W, combinations of these, and the like, Conductive compositions incorporating Mo are preferred. The backside electrical contact £4 may also help to isolate the absorber 20 from the support 22 to minimize migration of support constituents into the absorber 20, For instance, backside electrical contact 24 can help to block the migratio of Fe and Ni constituents of a stainless steel support 22 into the absorber 20. The backside electrical contact 24 also can protect: the support 22 such as by protecting against Se if Se is used in the formation of absorber 20.

[024] it is contemplated the photovoltaic article has at least a photoelectrically active layer 0. This layer is generally disposed above the flexible conductive substrate 10 and below the top transparent conducting layer 130. This layer functions to take the input from the incident Hgh^'i 18 and convert it Into electricity, it is contemplated that this layer may be a single layer of material or may be a multilayer composite of many materials, the composite, of which may depend upon the type of photovoltaic article 10 e.g. copper chaicogenide type ceils amorphous silicon, li -V (i.e. GaAs), il-iV (i.e. CdTe), copper zinc tin sulfide, organic photovoltaios, nanoparticie photovoltaies, dye sensitized solar ceils, and combinations of the ilka.

fQ2S] The group 18-1118 ohaieogenide (e.g. copper chaicogenide} cells are preferred. In this case the absorber comprises selenldes, sulfides, iellurides, and/or combinations of these that Include at least: one of copper, indium, aluminum, and/or gaiiium. More: typically at least two or even at least three of Cu, In, Ga, and Al are present, Sultides and or seienldes are preferred. Some embodiments include sulfides or selenldes of copper and indium. Additional embodiments includ selenldes or sultides of copper, indium, and gallium. Aluminum may be used as an additional or alternative metal, typically replacing some or all of the gallium. Specific examples Include but are not limited to copper indium selenldes, copper indium gallium selenides, copper gaiiium selenldes, copper indium sulfides, copper indium gallium sulfides, copper gaiiium sulfides, copper indium sulfide selenldes, copper gaiiium sulfide selenldes, copper indium aluminum sulfides, copper indium aluminum selenldes, copper indium aluminum sulfide seleoide, copper indium aluminum gaiiium sulfides, copper indium aluminum gallium selenldes, copper indium aluminum gallium sulfide seienide, and copper indium gallium sulfide selenldes. The absorber materials also may be doped with other materials,, such as Na, Li, or the like, to enhance performance, in addition, many ohalcogenide materials could incorporate at least some oxyge as an impurity in small amounts without significant deleterious effects upon electronic properties, This layer may be formed by sputtering, evaporation or any other known method. The thickness of this layer is preferably 0.5 to 3 microns.

[0261 in the copper chaicogenide cell the optional buffer and window layers may be considered part of either the active layer 120 or the transparent conducting layer 130 for purposes of understanding in what layers the channels ar© formed. However, preferably the buffer laye is considered part of the active layer 120 and the window layer ss considered part of the transparent conducting layer 130, [027| It is contemplated the photovoltaic article 10 has at least a top transparent conducting layer 130, This layer Is generall disposed above the photoelectrical!^ active layer 120 and may represent the outer most surfaee of the article (generally the surface that first receives the incident light This layer is preferably transparent, or at least translucent, and allows the desired wavelengths of light to reach the photoelectrical^^' active laye 20. .It is contemplated that this layer may be a single layer of material or may be a multilayer composite of many materials, the composition of which may depend upon the type of photovoltaic article 10 {^'e.g. copper chalccgenide type ceils (e.g. copper indium gallium seJehides, copper Indium seienides, copper indium gallium sulfides, copper indium sulfides, copper indium gallium selenides sulfides, etc.), amorphou silicon, ll!-V (I.e. G As), tMV (le. Cdle), copper zinc tin sulfide, organic photo oitaics, nanopaiticle photovoitaics, dye sensiffeed solar ceils, and combinations of the like. However, preferably the transparent conducting layer 130 Is a very thin metal film (such that It is at least somewhat transparent to light) or a transparent conductive oxide A wide variety of transparent conducting oxides; very thin conductive, transparent metal films; or combination of these ma be used, but transparent conductive- oxides are preferred. Examples of such TCOs include fluorine-doped tin oxide, tin oxide, indium oxide, indium tin oxide (ITO), .aluminum doped zinc oxide (AZO), zinc oxide, combinations of these, and the like. TOO layers are conveniently formed via sputtering or othe suitable deposition technique. The transparent conducting layer preferably has a thickness of from 10 to 500 nm_s more preferably 100 to 300 nm,

[028] It is contemplated that a number of channels will be "formed" into the article 10 in the process to produce the two or more thin-fiirn-based interconnected photovoltaic ceils. These channels function to separate the articl into individual cells and can be any number of shapes and sizes. It is contemplated that the channels may be formed via any numbe of processes, for example via mechanical scribe, laser ablation, etching (wet o dry), photolithography, or other methods common to the industry for selectively removing material from a substrate. The channels may he of various widths, depths, and profiles, depending on what may be desired and which channel is being formed (e.g. first, second, or third channels},. It is contemplated that the channels may be introduced to the article in the order stated below (e.g, preferably the first channel first, second channel second, third channel third) or in any other order if so desired. First C anne 140

[OSS] It is contemplated that the first channel 140 be formed through the flexible conductive substrate 110 (and any additional layers that m y exist on below or above the substrate) and to such a depth that at least a portion of the photoelectrical active layer is exposed. The first channel functions to both physically and electrically isolate two portions of the article (back s de) from each other, In a preferred embodiment, the first channel has a depth that at leas exposes a portion of the photoelectrical active layer and can .go into the photoeteetrically active layer, but not completely through it, U is also preferred that the first channel have a width that allows for the finished cells to flex ^'Without the channel closing up. In one preferred embodiment, the first channel has a • idt FCyi that can be about 1 μο to 500 ,um, it is preferred that the width is greater than about 10 pm , more preferably greater than about 25 μηι. most preferably greater than about 50 pm, and preferably a width less than about. 400 μΓΠ and more preferabl Jess tha about 309 μτη, most preferably less than about 2QQ urn.

Sec nd Channel ISO

30] It is contemplated that the second channel 180 be formed through the photooiectrically active layer 20 (and any additional layers that may exist on below or above It) and to such a depth that at. least a portion of the fiexibie conductive substrate is exposed (e.g. at least the electrically conductive portion of it). The second channel functions as a physical path that allows the at least two fhin-fiim-hased interconnected; photovoltaic eei!s to foe electrically interconnected (e.g. see the applying an electrically conductive material step). If Is contemplated that geometrically, the first and second channels b offset from one another, thus minimizing; the chance that the first and second channels combine to become a through-hole, i a preferred embodiment, the offset FSo can be about 1 pm to 500 .μτπ, It Is preferred that the offset is greater than about 10 μηι„ more preferably greater than about 25 μπ , most preferably greater than about 50 μτη, and preferably an offset less than about 400 am, and mora preferably less than about 300 μηι, most preferabl less than about 200 μητκ In a preferred embodiment, the second channel has a depth that at least exposes a portion of the fiexibie conductive substrate and can go into the flexible conductive substrate, but not completely through if, and most Importantly exposes the conductive material (see the applying an electrically conductive material step). It is also preferred that the second channel have width that allows for the finished cells to flex without the channel closing up. In one preferred embodiment, the second channel Has a width SG that can be^' about 1 μπι to §00 jim. It is preferred that t e---Wkftrt is greater than about 10 pm, mora preferably greater than about 25 .um, most preferably greater than about 50 μοι., and preferably a width less than about 400 μπ , more preferably lass than about 300 μη* and most preferably lass than about 200 μπι,

Thirst ..Chann l i?0

[03 It is contemplated that the third channel 170 be formed through the top transparent conducting layer 130 (and any additional layers that may exist on below or above the layers) and to the photoeiectricaily active layer to such a depth that at feast a portion of the photoefectnca!ry active layer is exposed,. The third channel functions to both ^'physically and electrically isolate two portions of the article (front side) from each other, it Is contemplated that geometrically, the third channel is off-set from the first and second channels. n a preferred embodiment, the offset TFSo can be about 1 μίη to 600 urn. it is preferred that the width is greater than about 10 urn, more preferably greater than about 25 μτη and most preferably greater than about 50 μηη, and preferably a width less than about: 400 more preferably less than about 300 urn and most preferabl lass than about 200 pm. In a preferred em odiment._! the third channel has a depth -that at least exposes portion of the photoelectrical iy active layer and can go into the phoioelectricaliy active layer, but not completely through it. it is also preferred that the third channel have a width that allows for the finished ceils to flex without the channel closing up. in one preferred embodiment, the third channel has a width TC_W that can be about 1 πΐ to 500 μπ?. ft is preferred that the width Is greater than about 0 ήι, more preferably greater than about 25 urn, and most preferably greater than about 50 ι, and preferably a width less than about 400 μ,Γή, and more preferably (ess than about 300 .m, most preferably !ass than about 200 pm,

[032] It is contemplated that "forming" of the various layers of the article 1Q may be achieved via numerous methods, for example as discussed above in the "channels" paragraphs, in one- - preferred embodiment, a mechanical scribe is utilized to make a ^"out. For example, with mechanical scribing, a diamond-tippeet stylus or blade may be placed in contact with the device and dragged across the surface of the device, physically tearing the underlying material in the path of the stylus. [033] It is contemplated thai: mechanical scribing, with the use of a diamond-tipped stylus or appropriate blade, may work for the softer semiconductor materials such as CdTe, copper indium gallium dise!enide (£103), and a--Si:H> it is believed "that tearing of the film is a: particular problem for films such as zinc oxide (ZnO) thai have low adhesion. Mechanical scribing of harder films such as molybdenum on glass invariably leads to scoring of the glass, which then contributes to increased risk of breakage in subsequent processing.

[034] ft is also believed that most of the problem encountered with mechanical scribing do not occur with laser scribing, in a recently completed a survey of laser systems, as applied to the thi.i>film materials used in the CdTe-base find CIS-based PV mo ui^(8ee;ht|p ^^

photovoiiaios-iasef-scribft which is incorporated by reference) has found that good scribes ca be obtained with a wide variety of pulsed lasers, such a Nd:YAG (lamp-pumped, diode-pumped, Q-switched, and roodeloeked), copper-vapor, and xenon chloride¹ and krypton fluoride exoimer lasers, it is believed that it may be Important when choosing a laser, to pay attention to the specific material properties (absorption coefficient, melting temperature, thermal diffusivify, and so on) of the films used in the solar cells.

p3§l it is contemplated that an insulation layer 150 may be disposed at o near the bottom of the finished ceils 100, One function of this layer may be to provide a protective barrier (e.g. environmentally and/or electrically) for the portions covered by this layer, keeping out dirt, moisture, and the like, it also can function to hold the cells 100 together, akin to "taping" two adjoining cells together. It is contemplated that layer 150 can span across substantially the entire bottom of the ceii 100 or just locally about the area of the channel 140, in a preferred embodiment, the insulation .layer 150 can have thickness !LT of about 100 nm to 1000 urn. It is preferred thai the thickness is greater than about i μηη, more preferably greater than about 25 ,um, most preferably greater than about 75 μηι, and preferably a thickness less than about 500 μπΊ , more preferably less than about 200 ι and most preferably iess than about 100 μηι,

0301 The insulatio layer may comprise any number of materials that are suitable for providing protection as described above. Preferred materials include: epoxy, silicone, polyester, poiyfluorene, poiyoiefia polyimide, polyamide, polyethylene, polyethylene tteerreepphhaaiiaattee,, fflluuoorrooppoorryymmeerrss,, ppaarraaiiyyeennee,, uurreeithhaannee,, e etthhyylleennee vviinnyyll aacceettaattee,, oorr ccoommbbiinnaattiioonnss^' ooff tthhee lliikkee,,..

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£089] H is contemplated that optionally some electrically insulating materia! may be disposed within the third channel (not shown). This material may function to provide a protective barrier (e.g> environmentally and/or electrically) tor the portions covered by the material, keeping out dirt, moisture, and the like. The electrically insulating material may comprise any numbe of materials that are suitable for providing protection as described above. Preferred materials include: silicon oxide, silicon nitride, silicon carbide, titanium oxide, aluminum oxide, aluminum nitride, boron oxide, boron nitride, boron carbide, diamond like carbon, epoxy, silicone, polyester, poiyfiuorene, poiyoiefin, polysmide, polyamide, polyethylene, polyethylene terephaiate, fluorepoiymers, paraiyene, urethane, ethylene vinyl acetate, or combinations of the like,

j¾40J It is contemplated that an electrically conductive material 180 is used in the process to interconnect the photovoltaic cells 1Q0_* In the present invention, the material is used In conjunction with the second channel and should be i contact wit an electrically conductive portion of the flexible conductive substrate 110 and the to of the top transparent conducting layer 130, The electrically conductive material may comprise any number of materials tha are suitable for providing electrical conductivity, but preferred materials include; The electrically conductive, material may desirably at least include a conductive metal such as nickel, copper, silver, aluminum, tin, and the like and/or combinations thereof. In one preferred embo iment, the electrically conductive material comprises silver. If is also contemplated that electrically conductive adheslves (EGA) may foe any such as are known in the Industry. Such ECA's are frequently compositions comprising a thermosetting polymer matrix wit electrically conductive polymers. Such thermosetting polymers inclu e- but are hot limited to fhermosef materials having comprising epoxy, eyanate ester,; maieimide,_. phenolic* anhydride, vinyl, ally! or amino functionalities or combinations thereof. The conductive filler particles may be for example silver, gold, copper, nickel, aluminum, carbon nanotubes, graphite, tin, tin alloys, bismuth or combinations thereof, Epoxy based ECAs with silver particles are preferred The electrically conductive material region can he formed by one of several known methods including but not limited to screen printing, ink jet printing, gravure printing, electroplating, sputtering, evaporating and the like.

j¾ 1J T^"he interconnected ceils formed by this method can be encapsulated or packaged within protective materials {encapsulants, -adhesives, glass, plastic films or sheets, etc) and electrically- interconnected of made electrically connectahle to power converters or other electrical devices to form photovoltaic modules that can be installed in the field or on structures to produce and transmit power.

[042] Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure,. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one: or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention,.

[043] The use of the terms "comprising" or "including" describing combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps,

[044] Plural elements, ingredients, components or steps can be provided by a single integrated element* ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of *a" or "one" to describe an element, ingredient, component or step is not Intended to foreclose additional elements, ingredients, components or steps. All references herein to element or metals belonging to a certain Group refer to the Periodic Table of the Elements published and copyrighted by CRC Press, Inc., 1989. Any reference to the - .Group or Groups shall be ^'to the Grou s or Groups as reflected in this Periodic Table of the Elements using the !UPAC system for numbering groups.

Claims

CLAIM What is claimed is:

1. A method of producing two or more thin-fiim-based interconnected photovoltaic cells comprising the steps of: a) providing a photovoltaic- article comprising: a flexible conductive substrate, at least one photoe!ectncaSly active layer, and a top transparent conducting layer; b) forming one or more first channels through the flexible conductive substrate to expose a portion of the photoeleetricaliy active layer; c) applying an Insulating segment to the ^'conductive substrate and spanning the one or more first channel; d) forming one or more second channels off set from the one or more first, channels through the phoioeiectflcaliy active layer to expose a conductive surface of the flexible conductive substrate^* f) forming one or more third channels off set from both the first channel and the second channels, through the top transparent conducting layer and to the photoelectrloaiiy active layer; and g) applying an electrically conductive material above the top transparent conducting layer and in the second channels, thus producing two or more interconnected photovoltaic cells.

2. The method according to claim 1 _< further comprising the step of at least partially filling the at least one third off-set channels with an electrically insulating material.

3. The method according to claim 2, wherein the electrically insulating material comprises silicon oxide, silicon nitride, titanium oxide, aluminum oxide, non- conductive epoxy, -silicone* polyester, poiyfluorerse, poiyoiefln, polyimlde,: polyarnide, polyethylene or combinations of the like. 4, The method according to any of claims 1 to 3» wherein the insulating layer comprises polyester, poiyolefin, polyimide, poSyarnide, polyethylene.

5, : The method according to any of the previous claims, wherein th forming step is earned out by scribing, cutting, ablating, or combinations of the like,

6, The method according to any of the previous claims,_, wherein the photovoltaic article cell is in roll form,

7, The method according to any of the previous claims, wherein the electricall insulating material functions as a bottom carrier film,

8, Th method according to any of the previous claims, wherein the third off-set channels of the forming step (fl go at least partially ^' -through the photoelectriealiy active layer,

9, The method according to any of the previous e-iaJm-s,. wherein the width of the channels of the formin step are from 10 to 500 microns,

10, A photovoltaic article formed by the method of any one of claims 1 to

9,